Casing, process of formation of casing in boreholes by additive method and device for its formation

ABSTRACT

The invention lies in the gradual treatment of rocks vapours in a mixture of carrier and cooling gases and their gradual applying in layers which are forming a casing on walls of a borehole. The invention includes the adjustments of various quantities and types of additives in the layers and the additive method applied materials by their autonomous self-cooling without the need for external coolant by heat exchange between materials in various layers, where it forms the casing on the walls of the borehole. It describes functional parts and their interconnection: arrangement of cooling parts, separators, accelerating and mixing elements, mechanisms for their adjustments which allow forming the casing on the walls of the borehole with the possibility to influence the resulting characteristics of the casing according to demands and functional requirements in the place of the borehole.

RELATED APPLICATIONS

This application is a continuation-in-part of International PatentApplication No. PCT/SK2013/050008, filed Oct. 22, 2013, which is herebyincorporated by reference in its entirety, and which claims priority toSlovakian application No. PP50048-2012, filed Oct. 24, 2012.

TECHNICAL FIELD

The invention relates to a casing, a process of formation of a casing byadditive method, especially in contactless thermal drilling of boreholesin geological formations and a system for its performing.

BACKGROUND ART

For strength and resistance of borehole walls, the high-quality casingis essential condition for technological use of the borehole during itsexcavation as well as its durability.

The issue of parallel formation of the casing and drilling process hasproceeded through several stages of development. Experiments have beenmade to solve the issue of narrowing the borehole profile as well as thecasing (tapering) by solutions such as expansion of the embedded casingprofiles and also by methods of passive insertion of casing during thedrilling. Among the first conceptions of casing drilling was the patentU.S. Pat. No. 3,661,218. That patent protects a method of casingdrilling, but maintains the deficiencies of the rotating drill string ofconventional mechanical drilling columns, namely decrescentcross-section.

Solutions which can be considered useful and were designed and put intopractical use are the principles of drilling with the casing. Analysisof this technology is described in detail in R. Tessari Atall: “Drillingwith casing promises major benefits” in Oil & Gas Journal Vol 97, No. 201999 and the article of authors Okeke et al. “Current Trends and FutureDevelopment in Casing Drilling”. In patent literature the casingdrilling, as an example among others, is the object of a patent ofcompany Tesco U.S. Pat. No. 6,705,413. The company Halliburton has apatent for drilling with a casing for directional drilling in the patentU.S. Pat. No. 6,877,570. Both mentioned patents have the main commondeficiency that the rotating casing may be threatened by collapse ofunstable rock from outside and thus by the complete discontinuation ofthe drilling process. The second common deficiency is that the rotatingcasing is uncementable during the whole drilling process or it iscementable in parts, and the narrowing casing must also be used for thenext section.

Utilization of thermal, especially plasma, technologies in formation ofa casing is the closest issue to the present invention. These solutionscan be divided into two categories. The first includes solutions basedon the so-called penetrators i.e. devices, a tip of which heated to thetemperature above the melting point of the rock is depressed into therock, in which it forms a melting vitrified layer and removes the excessmaterial. The second category includes solutions based on plasma thermalflux /torch/, which melts the rock at the bottom and on the walls of theborehole at its exit from the bottom of the borehole.

The example of the first group of solutions is the patent U.S. Pat. No.3,693,731 “Method and apparatus for tunnelling by melting” by D.Armstrong E. et al., which describes a conical penetrator, whichdepresses the melt into the pores of the surrounding rock and thus itforms a partially vitrified casing. A large amount of energy is requiredto achieve acceptable efficiency of the process and speed ofpenetration.

The line of direct action of heat flux of plasma flow to rock completesthe solution of the patent U.S. Pat. No. 8,235,140 by Wideman T. W. etal. using the mode of so-called spallation, which is energeticallypreferable. It forms a disturbed layer which may be impregnated and thusit can form a temporary casing. However, the casing formed in this wayshows insufficient strength.

The patent U.S. Pat. No. 6,591,920 by Foppe W. uses a molten metalsupplied from the surface and heated to a temperature high above themelting point as drilling thermal medium. It depresses the melt intocracks in the rock and thereby forms a casing. But the whole process isconsiderably technologically difficult. The patent U.S. Pat. No.6,851,488 by Samih Batarseh describes the formation of a casing by heatradiation flux of laser radiation, which forms a rock melt. It usescompressed air to hold the melt on the wall, and the entire borehole isfilled with air as well.

The present invention eliminates the deficiencies of the above mentionedpatents in forming of a casing and in the field of efficiency, materialand temporal parameters and in particular functionality of casing beingformed such as forming of pipe in the casing, sandwich and compositestructure of the casing and thereby it surpasses them.

The above-mentioned U.S. Pat. No. 6,851,488 of Samih Batarseh: “Laserliner creation apparatus and method”, discloses the process (method) andapparatus of creation of the borehole liner by melting the surroundingrock and the cooling and perforating the rock by fluid flow throughnozzles. This is the basic difference to the present invention which isbased on additive layering of the processed material of the rock andadditives to create homogenous layer with the composite composition, andwith controllable properties and high strength given by additives.

The U.S. Pat. No. 6,851,488 belongs to the “penetrator” category whichhas substantial drawbacks:

-   -   a) the resulting structure is influenced by non-homogenous rock,        by existing fracks etc., gives no guarantee of quality of the        created liner with low strength parameters, the melted rock        under the gravitation influence is flowing down and deformed        until the cooling fluid flow is applied,    -   b) it does not solve the vital problem of the transporting        simultaneously with the liner creation, and    -   c) the penetrator concept is generally failed on wrong        assumption that the excessive melted rock is pushed into the        surrounding rocks fracks. This is the lethal drawback in the        referenced patent U.S. Pat. No. 6,851,488.        The present invention solves these problems in principal way and        has the liner composition under full control by additive process        as it is solving the transport of melted/evaporated material to        the surface.

The patents U.S. Pat. No. 3,907,044 and U.S. Pat. No. 5,735,355 are ofpenetrator melting category and are not relevant to the additivelayering concept of this invention.

DISCLOSURE OF INVENTION

The mentioned deficiencies are to the great extent eliminated by acasing, a process of formation of the casing by additive methodespecially in thermal drilling of boreholes in geological formations,and devices for its formation according to the present invention. Thecasing determines and ensures a workspace of a borehole by itsfunctions. It forms an integral part of the functioning borehole and itsoperation. The nature of the present invention consists in that thecasing is formed by layering material from vaporized rocks bycondensation and solidification on borehole walls. The casing is applieddirectly onto the walls of the borehole and over conventional sheeting,which sheeting is inserted into the borehole and does not need to meetvery high requirements, as it is put on it mainly because ofinstallation and handling. In formation of the casing, the material ofthe vaporized rock and thermal energy inserted into it are used so thatby a heat treatment a mixture of rock vapours passes through phasetransformations, namely to a liquid phase and a partially solid phase,and mechanical treatments and transport of the rock material from asource of generation of hot gas mixtures, namely mixtures of rockvapours and coolant vapours, to an area of formation of the casing bydirecting and application of the treated rock material in the area ofthe casing formation to the borehole wall or to the underlying layers ofthe casing being formed. The layered casing is formed by cooling therock material, wherein the casing layers formation is continuous. Theadvantage of the additive method of casing formation lies in applicationof the casing alone, which, unlike impressing—penetration—mechanisms,allows to create boreholes with casing having characteristics similar tothose of structural embodiments of boreholes designed today.

In thermal drilling, the main advantage over conventional drillingtechnologies is the possibility to form the casing directly fromdisintegrated material. The object of the present invention is formationof the casing by additive process from melted and vaporized rockmaterial applied in the layers to the borehole walls, by which thecasing achieves required characteristics, such as tensile strength,compressive strength, compliance, permeability, porosity, thermalinsulation properties and others.

Rocks material meltdown and vaporization occur especially in thermaldrilling of boreholes, where from them and from coolant transported tothe place of drilling are generated the hot gas mixtures consisting ofrock vapours and coolant, where cooling gases are formed by itsvaporization, wherein by taking over the carrying function, also carriergases are subsequently used for formation of the casing by additivemethod in the process of formation of the casing according to thepresent invention.

The heat treatment is a cooling, in which the generated hot gas mixturesare cooled by coolant. A phase transition of a rock vapours occurs bytheir cooling and by condensation liquid particles of rock and bysolidification solid particles of rock are formed in the flowing mixtureof rock material and cooling gases.

The generated hot gas mixtures of rock vapours and cooling gases aredivided by mechanical treatment into at least two main streams. At leastone stream is a stream of cold materials and at least one stream is astream of hot materials.

Since not the entire material from melted and vaporized rocks isnecessary for formation of the casing, it is necessary to separate theexcess part of this material together with the cooling gases from thepart which will be used for formation of the casing. Therefore at leastfrom one of these main streams other sidestreams are further continuallydiverging, by which excess mixtures of rock materials and cooling gasesare led away to the waste. The part of the rock material from which thecasing will be formed remains in the streams of cold and hot materials.

At least one stream of hot materials and at least one stream of coldmaterials are formed by heat treatments which is a multistage cooling ofrock materials by controlled heat transformation, wherein at least twomain streams are cooled to different temperature so that the stream ofcold rock materials is cooled to the temperature at which gas rockmaterial is transformed into the solid phase and solidifying rockparticles are formed, which solidify before their application as thecasing layer, and the stream of hot rock materials is cooled above thetemperature of the rock melting, which allows them to be mixed with coldmaterials and thus to form the continuous casing layer, in which layersduring the heat exchange between particles occur temperature decrease ofentire layer, phase transformation and thus formation of continuouscasing layer. Temperature of particles in the stream of cold materialsand in the stream of hot materials is different before application ofthe casing layer.

Waste gases, which are excess parts of cooling gases, are led away tothe waste from main streams of materials by further mechanicaltreatments, namely by separation, and thus the streams of solidifyingrock particles formed by cooling the mixtures of hot rock vapours andcooling gases, which are at the same time the carrier gases, areconcentrated.

Discharge of waste cooling gases is necessary also because the coolantis continuously added as cooling and as protective and separating layerbetween all contact areas of the device and the mixture of hot flowinggases. Since during the process of drilling and also for the process ofthe casing formation it is constantly necessary to supply coolant, it isalso constantly necessary to separate excess parts of cooling gases frommain streams of materials and to discharge them into the waste. Theconcentration of mixtures of main streams, which already containsolidifying parts formed by cooling the hot rock vapours mixtures in thestream of cooling gases, is accomplished by discharge of the excessparts of cooling gases.

Cooling gases are formed by vaporization of supplied coolant and coolinggases also take over the carrying function, since they simultaneouslycarry rock particles, which solidify in the system, and therefore theyare also carrier gases. Removed heat and temperature decrease of theresulting mixture is performed by phase transformation of the coolant,mixing the parts of the mixture and expansion of the mixtures ofvaporized rock and cooling gases.

After dividing and separating the mixtures of excess rocks material andcooling gases, the streams of the mixtures of rock material and coolinggases are divided into smaller streams by mechanical treatment, namelyby division into n number of channels, for the purpose of theiradditional treatment.

The step of separation of the excess parts of cooling gases is followedby further mechanical treatment, namely increasing the speed of cold andhot rock particles before mixing them, which is performed to accelerateand direct them.

The coolant also provides thermal protection to the device so that thecoolant is continuously added as a cooling and also protective andseparating layer between all contact areas of the device and the mixtureof hot flowing gases.

Mixing of cold particles and hot particles occurs by connecting thestream of cold materials with the stream of hot materials, and themixture of rocks material is formed, which is at first applied to theborehole wall and subsequently additional layers are applied on theunderlying layers of the moulded casing.

The formed casing layer solidifies especially during further heattreatment, which is self-cooling, wherein internal heat transfer occursin the applied layer, namely by heat exchange between applied hot andcold particles of the rock material in the casing layer. In the area ofcasing formation, a moulding device is embedded, by sliding of which anaperture is formed in the solidifying casing, which forms pipe channelsin the layered casing along the borehole. A medium supply such as acoolant pipeline, an electricity conductor, a signal conductor andothers, is conveyed to the slid moulding device.

Mixing of cold and hot rock particles is performed by action of opposingcentrifugal forces, which empty into a common area in a channel offormation of casing layers leading into the area of application ofcasing layers.

Cooling of the formed casing must be controlled, wherein the formedcasing layers are tempered and cooled. Hot waste gases, alternativelycooled by addition of cooling gases, are preferably used for controlledcooling of the casing.

Cooling and condensation of discharged waste rock material providecooling of cooling gases and excess rock material to the temperature inthe range of 100-250° C.

By sliding of one or several moulding devices in the solidifying casing,an aperture is formed, which shapes the pipe channel in the layeredcasing along the borehole, where a medium supply, in particular acoolant pipeline, an electricity conductor, a signal conductor andothers, is conveyed to the slid moulding device. Connected mediumsupplies, which are led by the formed aperture from the surface of theborehole, are also slid by sliding of the moulding device.

In order to improve the properties of the casing, it is advantageous toadd specialized additives to the flowing mixture, which comprise:

-   -   a. an increased supply of coolant for controlling the cooling of        the mixture of rock vapours and cooling gases in order to form        expansion joints in the casing using controlled cooling of        applied material; and/or    -   b. reinforcement elements in order to improve the mechanical        properties of the casing;

and/or

-   -   c. a foaming additive in order to adjust thermal-insulating and        mechanical properties of the walls of the casing.        Addition of particular additives is preferably performed before        mechanical treatment of increasing the speed of cold and hot        parts, and especially before mixing them in the process of        acceleration of particles, namely by addition of additives to        various sub-groups of n number of channels and thus materials        are formed, which after application form one or more coaxial        structures with the same or different characteristics, and        thereby a sandwich and composite structure is formed in the        casing.

The resulting casing consists of several layers, wherein some of thelayers contain a certain quantitative volume of additives (up to ratio100%), and with regard to the type and amount of the added additives,not only are the properties adjusted reciprocally among individualapplied casing layers, but also properties of differing concentric partsof the formed casing can be adjusted, and thereby they form sandwich andcomposite aggregations and thus adjust properties of the entire casing.

A device for performing the process of formation of the casing byadditive method, especially in thermal drilling of the boreholes ingeological formations according to present invention, comprises thefollowing technological parts:

-   -   a hot rock vapours mixture formation module;    -   mechanical treatments modules;    -   heat treatments modules;    -   transport modules;    -   directing and application block.

A hot rock vapours mixture formation and cooling gases module is ahigh-temperature energy flow, which produces the vaporized rock forminghot rock vapours mixed with cooling gases entering into the casingformation.

The mechanical treatments module includes:

-   -   a mechanical division and separation block;    -   a separation and concentration block;    -   particles division and acceleration blocks;    -   a system for mixing the particles;    -   an output streams separator.

The heat treatments module includes:

-   -   a cooling system;    -   a controlled cooling block.

The hot gases mixture cooling system is a group of channels, in whichthe hot mixture is cooled by the coolant in order to change the phase bycooling. By cooling, both liquid and solid particles of rock are formedin the flowing mixture. The group of channels of the cooling system isalso designed for protection of walls of active and exposed parts of thedevice.

The block for directing the application includes a casing layersformation channel. This channel is a mixing slot, where solid and liquidparticles of the flowing mixture are applied on the wall by kineticenergy and then they are deposited as the casing layers. Afterapplication, the hot particles in the layer are cooled autonomously,without the need for external cooling, with heat interchange between thehot and cold deposited fractions. And the casing layers formationchannel is designed for discharge of cooling gases and excess particlesof rock into the waste as well.

The mechanical division and separation block consists of a system ofbranching channels and separators separating volumes of the mixture ofrock materials and cooling gases into the other blocks, as necessary.

Additional functions mechanisms may be controlled dispensers for addingthe additive and these dispensers may be:

-   -   a. a dispenser of coolant for cooling the hot and cold material        for separation/disruption of the formed casing by the expansion        joint, and/or    -   b. dispensers of reinforcing concrete elements for improving the        mechanical properties, and/or    -   c. dispensers of foaming additives for improving and treatment        of thermal-insulation and mechanical properties of the casing        walls.

The device comprises also a system of channels for additives dosagecontrol into sub-groups of n number of channels in particles divisionand acceleration block, where it generates several treated streams ofmaterials. These streams of materials form coaxial sandwich andcomposite structures of the casing not only along the layers which arelayered in the casing, but also in radial direction relative to the axisof the borehole.

The separation and concentration of the mixtures of rock particles andgases block is a group of separators, by which division, separation anddischarge of the cooling gases is performed in the guide channels, wherethe cooling gases are separated and the mixtures of rock particles andgases are concentrated to the desired concentrations.

The particles acceleration blocks are accelerating centrifugal devicesincreasing the kinetic energy of particles.

The system for mixing the particles of hot and cold streams fromdirecting and accelerating part is a flow mixer of flowing cold and hotmaterials into the casing formation channel, wherein the particles arein the step of directing and acceleration directed and applied in thecasing layer in the casing formation channel.

The device also preferably comprises a block of sliding forms ofpipelines in the casing, which is a system of forming members, which aredesigned for formation of the pipe channel in the layered part of thecasing along the borehole.

The output streams separator is a separator at the outlet of the casingformation channel, which separates excess materials discharged out ofthe casing formation channel and parts of the hot gases for temperingthe casing by controlled cooling.

The controlled casing cooling block is a tempering and cooling system atan interface of the casing and the device.

The device also comprises a waste outlet, by which the collecting andcooling device discharges all excess rocks and cooling gases materials,which are cooled to the temperature below the temperature of the deviceresistance.

The system for mixing the particles consists of two systems ofcentrifugal channels, which are orientated against each other, whereinthey may together form an obtuse angle, and they lead into the commonarea in the casing layers formation channel.

The hot mixture formation block may preferably have an annular shape ofcross-section similar to the casing being formed; thereby it allowsperforming standard mechanical drilling or core drilling in the centralarea of the annular casing formation.

The present invention has the following advantages when compared to theprior art:

The present technology uses the disintegrated rock material itself andthe energy inputted in them in eroding to form the casing. Due to thecasing formed according to this invention, the borehole is stabilizedand protected against invasive action of materials from geologicalaction of surroundings. By formation of the composite and laminatedcasing, the mechanical properties of the borehole are structurallyimproved. The casing of the walls is corrosion resistant and from thispoint of view it has longer lifetime. The logistical procedures ofconventional technology are eliminated, thus reducing time demands andfinancial burdens of the deep boreholes formation.

DESCRIPTION OF DRAWINGS

FIG. 1 shows a technological scheme of casing formation.

FIG. 2 shows a scheme of the mechanisms of casing formation by additivemethod.

FIG. 3 shows a cross section of the borehole as the base for foamingannular casing and pipes for distribution of media and supply of energy.

FIG. 4 shows a flow of cold and hot materials and their mixing in thecasing layers formation channel.

FIG. 5 shows conical pipe formation.

FIG. 6 shows a layered formation of the casing by different functionalparts in the radial direction.

EXAMPLE OF THE EMBODIMENT

The formation of the casing from the disintegrated rock 18 according tothis invention is given by the sequence of treatment processes andcoating of the rock vapour materials in the casing layers, by theirautonomous cooling, when the casing is formed on the walls of theborehole 17. The casing is formed from applied layers of materialshaving different properties. The layers of materials with differentproperties are formed by sandwich-composite structures of preferredstrength properties. In the process of formation, the layers undergo acontrolled phase transition and are connected together. They contain thecrystalline structure of the desired properties, which, in the processof their formation, were solidified in the individual layers, therebycreating the crystalline structures of the preferred strengthproperties. These layers comprise reinforcement materials, which wereadded as additives to the liquid materials, and thus reinforce theparticular solidified layers and the resulting casing. The casing mayinclude transport channels for transport of material. This occurs in thecasing formation, which provides the formation of the casing especiallyin the thermal drilling of the boreholes 17 in geological formations ofrocks 18 according to the invention, in which one preferred embodimentis described in the following steps.

The hot mixture of the rocks vapours and coolants vapours, which incertain phase of the technological process become carrier gases, withthe temperature higher than the boiling point of each of the rocksfractions, enters the input part of the device for casing formation byadditive method, i.e. the hot mixture formation generator 1. In theblock 2 of the mechanical distribution, this mixture of rocks vapoursand coolant vapours is divided into two main streams. Both main streamsare selectively and controllably cooled, each in its cooling block 3 todifferent technological temperatures. One stream is cooled so that themain and essential part of the flow is condensed and subsequentlysolidified particles. This stream, preferably containing 60-90 weight %relative to the weight of the vaporized material flow of the enteringmixture of rock vapours and coolant vapours, is a stream of coldmaterial. From the stream of cold material, the excess mixtures of rocksvapours and coolant vapours are discharged into the outlet channel ofwaste material treatment, preferably in an amount of 50-70 weight %relative to the weight of flow of vaporized material, which does notparticipate in the formation of the layered casing 13, prior to itsfurther treatment. In the second flow of the mixture of rocks vapoursand coolant vapours, preferably containing 10-40 weight % relative tothe weight of flow of vaporized material of the entering, these mixturesare cooled so that the main and essential part of the flow are gaseousand liquid fractions, and thereby the nature of the flowing of hotmaterial is given.

All parts of the device, which come into contact with streams of flowinggases and high temperature vapours, are necessarily protected from theirthermal effects. Protection is carried out by the surface cooling offunctional bodies of the device, namely by continuous addition of thecoolant. Except for the mentioned protective function, the coolant alsoperforms a technological function, wherein the controlled cooling of themixture of gases and vapours is controlled by its amount, namely byblending it in the mixture of gases and vapours; thereby the finalmixture reaches the required temperature at which it has the desiredfunctional properties. Heat transfer between coolant being mixed androck vapours uses the latent heat by phase transition of the coolant andthe heat consumed by the expansion of the mixture of the vaporized rockand cooling gases for cooling the final mixture. Addition of the coolantis controlled and realized by the cooling block 3.

By adding further coolant to the mixture of rocks vapours and coolantvapours, the total volume of flowing mixtures is increasing and therebytheir temperature is decreasing and required fractions for furtherprocessing are being formed. The flowing mixture consists oftechnological fractions, i.e. of the rock material in a gas and/orliquid and/or solid phase, and of refrigerants. Excess cooling gases,which fulfil also the function of the carrier gases, are separated inthe separation block 5 and discharged into the outlet channel for wastematerial. The concentrated stream of gases and solidifying particles ofrock continues to the area, where additives of reinforcing elementsand/or foaming reagent in the line of cold materials are added or thehot concentrated mixture is cooled in order to form expansion joints bycontrolled cooling in the lines of cold materials and hot materials.Injection of additives is provided by mechanisms 4 of additionalfunctions.

In both streams, namely in the stream of cold materials and in thestream of hot materials in particles distribution and acceleration block6 streams of mixtures are divided into three groups of channels, and inthe first group are 6 pairs of channels, in the second group are 6 pairsof channels, and in the third group are 12 pairs of channels. Thesegroups of channels are arranged so that they cover the whole surface ofthe casing width. The pairs of channels refer to two channels connectingtwo streams into one. One channel is for cold material and the otherchannel is for hot material. Into the groups of channels, variousadditives are added, and thereby different mixtures of materials areformed and these flow in the appropriate groups of channels. In thefirst group, the material is treated so that the additives ofreinforcement elements are added. The material modified in this way isfurther divided into 6 pairs of channels. In the second group, thematerial is not modified by adding additives. The material modified inthis way is further divided into 6 pairs of channels. In the thirdgroup, the material is modified so that the foaming additives are added.The material modified in this way is further divided into 12 pairs ofchannels. Streams of mixtures of rocks vapours and coolant vapours arethen accelerated to increase their kinetic energy. Increasing the speedof the particles is performed for the purpose of acceleration anddirection, especially in the direction of the normal to the layers ofthe casing by inputting the kinetic energy into the cold particles andhot particles in the accelerating sections before entering into theblock 9 of directing the application from which the mixed stream isapplied to the surface of the walls, thereby forming the casing itself.Outlets of the channels of cold materials and hot materials of thestreams are situated alternately in the system 7 for mixing parts ofrocks and carrier gases, wherein the mixing of hot and cold materialoccurs by the outflow from each of these channels, wherein solid andliquid fractions are applied perpendicularly to the wall of the casing(FIG. 3). Different properties of materials flowing from differentgroups of channels allow to apply mixtures with different concentrationsof cold particles, hot particles and additives, and thereby the appliedlayer (FIG. 6) forms the sandwich and composite arrangement withadvantageous properties of the casing not only by modification of theproperties of the applied layers over time, but also by applyingdifferent materials from the groups of channels in the direction of theaxis of the applied casing.

Materials flowing against each other are mixed by the effect of thecentrifugal forces and form a layered casing 13 applied to the wall orsubsequently to the underlying, already applied casing layer 14, whereinthey solidify by self-cooling during heat transfer in the applied layerbetween deposited hot, liquid and cold particles of the intermingledstreams of cold materials and hot materials in the applied casing layer14. Each new layer of the layered casing 13 of applied material isthrown from the block 9 for directing and application from the nozzlesto the surface, and then diagonally across the surface of the conicalarea onto the already cooled layers of the applied casing 14, whereindifferent properties of various tubular parts of the final appliedcasing 14 are achieved by application of various and variously mixedmixtures with a differing content of additives being admixed by a system7 for mixing the parts of rocks and carrier gases, which empties intothe block 9 for directing the application.

Cooling gases and residues of non-applied rock particles are lead awayalong the casing being formed into an exit block 12 for waste productstreatment. The casing is temperated by controlled cooling of the wastemixtures using the hot vapours, which allows inside tensions in theformed casing to relax and to temper the casing by the separated vapoursand gases of the discharged and excess material in the separator 10 ofoutput streams, which are not involved in the formation of the casingand is lead away into the waste part of the device.

In the exit block 12 for waste products treatment, all fractions ofresidual/surplus material are cooled, wherein they are mixed to thefinal temperature of the carrier hot and cooling gases and residual rockmaterial, most preferably in the range of 100-250° C., less preferablyin the range of 200-450° C.

In the formed peripheral casing layer (FIG. 4), the pipelines are aimedby the moulding device 16. By sliding the moulding device 16 in one sucha pipeline, the aperture (FIG. 5) is being formed in the solidifiedcasing in the direction of the casing formation, which forms the pipechannel along the borehole 17. To the body of the shifted mouldingdevice 16 of the piping formation block 8 the supply 15 of a medium,such as water, conductor of electricity, signal cables and others, isconnected.

The sequence of preparation and formation of the casing is shownschematically in the FIG. 1.

LIST OF REFERENCE SIGNS

-   1. A hot mixture formation generator-   2. A mechanical division block-   3. A cooling block-   4. Additional functions mechanisms-   5. A separation block-   6. Distribution and acceleration of particles blocks-   7. A system for mixing parts of rocks and carrier gases-   8. A pipeline forming block-   9. A block for directing the application-   10. An output streams separator-   11. A casing controlled cooling block-   12. An exit block for waste products treatment-   13. A layered casing-   14. An applied layer of a casing-   15. Media supplies-   16. A moulding device-   17. A borehole drilled by conventional or other technology-   18. A rock

1. A casing designated for reinforcement and/or sealing of boreholewalls characterized in that the casing comprises at least one layer of amaterial applied to a rock, or to a previous layer of the casing,wherein the at least one layer comprises solidified bonded addedmaterials of rocks and additive particles, thus forming a layer ofpreferred strength properties.
 2. The casing according to claim 1characterized in that the additives are reinforcing elements and/orfoaming additives.
 3. The casing according to claim 1 characterized inthat the casing is multi-layered, and layered structures of differentproperties are formed because of the content of the additives in eachlayer and layered structures thereby preferably achieve properties ofcomposites.
 4. A process of formation of the casing according to claim 1in boreholes in additive method namely in thermal drilling in geologicalformations, characterized in that a vaporized rock and thermal energyinserted into said vaporized rock are used for formation of the casingso that a mixture of rock vapours is thermally and mechanically treated,wherein: a thermal treatment is cooling by a coolant during which aphase transition occurs and, by condensation, liquid particles of rockare formed, and, by solidification, solid particles of rock are formedin a flowing mixture of gaseous, liquid, and solid particles of rocksand cooling gases, by mechanical treatments, the generated hot gasmixtures of the rock vapors and vaporized coolant are divided into atleast two main streams, of which at least one stream is a stream of coldmaterials and at least one stream is a stream of hot materials, and atleast one of these streams is further branching into furthersidestreams, by which excess mixtures of rock materials and coolinggases are exhausted into the waste, wherein the stream of cold materialsis cooled to the temperature at which the gaseous material of the rocksis transformed into the solid phase and solidifying particles of rocksare formed, the solidifying particles of rocks solidify before theirapplication as a layer of the casing, and the stream of hot materials iscooled to the temperature which is above the melting temperature ofrocks and the stream of hot materials, after mixing with the coldmaterials, forms a mixture that is cooled below the solidification pointof rocks and thus it forms a solid continuous casing layer, transport ofthe rock material from a source of generation of hot gas mixtures,namely mixtures of rock vapours and coolant vapours to an area offormation of the casing by directing and application of the treated rockmaterial in the area of formation of the casing to the borehole wall orto the underlying layers of the casing being formed and by cooling therock material, the layered casing is formed, wherein the formation ofcasing layers is continuous.
 5. The process of formation of the casingaccording to claim 4 characterized in that only a part of the rockmaterials from which the casing will be formed remains in the stream ofcold and hot materials.
 6. The process of formation of the casingaccording to claim 4 characterized in that at least one stream of hotmaterials and at least one stream of cold materials are formed by heattreatments which is a multistage cooling of rock materials by controlledheat transformation.
 7. The process of formation of the casing accordingto claim 4 characterized in that, waste gases, which are excess parts ofcooling gases, are exhausted to the waste from main streams by furthermechanical treatments, namely by separation, and thus the streams ofsolidifying rock particles formed by cooling the mixtures of hot rockvapours and cooling gases, which are at the same time the carrier gases,are concentrated.
 8. The process of formation of the casing according toclaim 4 characterized in that one of the heat treatment method is acooling by expansion of mixtures of vaporized rock and cooling gases. 9.The process of formation of the casing according to claim 4characterized in that after dividing and separating the excess mixturesand cooling gases, the streams of the mixtures of rock material andcooling gases are divided by mechanical treatment into smaller streamsfor the purpose of their different treatment, and each of these smallerstreams is further divided into other smaller streams.
 10. The processof formation of the casing according to claim 4 characterized in thatthe step of separation of the excess parts of cooling gases is followedby further mechanical treatment, namely increasing of speed of cold andhot rock particles before mixing them, which is performed in order toaccelerate and direct them.
 11. The process of formation of the casingaccording to claim 4 characterized in that the coolant also providesthermal protection to the device so, that the coolant is continuouslyadded as a cooling and also protective and separating layer between allcontact areas of the device and the mixture of hot flowing gases. 12.The process of formation of the casing according to claim 4characterized in that by further mechanical treatment, namely by mixingof cold rock particles and hot rock particles, a mixture of rockmaterial is formed, which is applied to the borehole wall, wherein itforms the first casing layer, and then the further casing layers areaimed so that the mixture of rock material is applied onto theunderlying layers of the formed casing.
 13. The process of formation ofthe casing according to claim 4 characterized in that the formed casinglayer solidifies during further heat treatment, which is self-cooling,wherein internal heat transfer occurs in the applied layer, namely byheat exchange between applied hot and cold particles of the rockmaterial in the casing layer.
 14. The process of formation of the casingaccording to claim 4 characterized in that in the area of casingformation, a moulding device is embedded, by sliding of which anaperture is formed in the solidifying casing, which forms pipe channelsin the layered casing along the borehole, where a medium supply such asa coolant pipeline, an electricity conductor, a signal conductor andothers, is conveyed to the slid moulding device.
 15. The process offormation of the casing according to claim 4 characterized in thatmixing of cold and hot rock particles is performed by action of opposingcentrifugal streams of mixtures, which empty into a common area in achannel of formation of the casing layers leading into the area ofapplication of casing layers.
 16. The process of formation of the casingaccording to claim 4 characterized in that cooling of the casing iscontrolled by further heat treatment, in which hot waste gases are used,which are controlled by mixing with the coolant so that they temperand/or cool the formed casing.
 17. The process of formation of thecasing according to claim 4 characterized in that cooling andcondensation of discharged waste rock material provide cooling ofcooling gases and excess rock material to the temperature in the rangeof 100-250° C.
 18. The process of formation of the casing according toclaim 14 characterized in that by sliding the moulding device, alsoconnected supplies of media are slid in the formed apertures, inparticular of media such as coolant pipelines, conductors ofelectricity, signal conductors, and others, which are led by a generatedaperture to the surface of the borehole.
 19. The process of formation ofthe casing according to claim 4 characterized in that specializedadditives are added, which comprise: a. an increased supply of coolantfor controlling the cooling of the mixture of rock vapours and coolinggases in order to form expansion joints in the casing using controlledcooling of applied material; and/or b. reinforcement elements in orderto improve the mechanical properties of the casing; and/or c. a foamingadditive in order to adjust thermal-insulating and mechanical propertiesof the walls of the casing.
 20. The process of formation of the casingaccording to claim 4 characterized in that addition of particularadditives is performed before mechanical treatment for increasing thespeed of cold and hot parts, and especially before mixing them in theprocess of acceleration of particles.
 21. The process of formation ofthe casing according to claim 4, characterized in that by differenttreatment of streams by addition of additives into the groups ofchannels, different materials are formed, which are further divided andafter application they form one or more coaxial structures with the sameor different characteristics, and thereby a sandwich and compositestructure is formed in the casing.
 22. A device for performing theprocess of formation of the casing in additive method, namely in thermaldrilling of boreholes in geological formations according to claim 4characterized in that it comprises the following technological parts: ahot rock vapours mixture formation module, mechanical treatmentsmodules, heat treatments modules, wherein: the hot rock vapours mixtureformation module contains a high-temperature energy flow generator (1),which produces the vaporized rock and forms hot rock vapours being mixedwith cooling gases entering into the casing formation; mechanicaltreatments modules comprises: a mechanical division and separation block(2) for mechanical division of hot rock vapours and cooling gases andseparation of hot rock vapours, which contains a separator of solid andgas rock vapours and a flow regulator of hot vapours, and consists of agroup of inlet and outlet channels of the mechanical division block (2),particles division and acceleration blocks (6) for division andacceleration of hot gas vapours and additive particles, which contain asystem of branching channels and separators separating volumes of themixture of rock materials and carrier gases and each separated branchcontains an accelerator at the outlet of the division and separationblock (6), a system (7) for mixing the particles of hot and cold streamsbefore application of hot gas vapours, additive particles, and coolinggases, which is formed by a system of inlet and mixing channels anddirecting outlet nozzles, a separator (10) of outlet streams ofnon-applied hot gas vapours, additive particles and carrier coolinggases, which consists of a collector of a liquid and solid parts ofrocks and channels of cooled gases of rock vapours and cooling gases,which empty into a block (11) for controlled cooling of the casing; heattreatments modules contain a cooling block (3) for cooling of hotmixture of rock vapours and cooling gases and said cooling block forcooling of the hot mixture of gases contains a channel grouping of thecooling block (3), in which the hot mixture of gas vapours is cooled bya coolant in order to achieve a phase transition, wherein, by cooling,liquid parts of the rock are formed in a flowing mixture of carriercooling gas and rock vapours.
 23. The device for performing the processof formation of the casing according to claim 22 characterized in thatthe cooling block (3) is a grouping of channels which forms also asystem for protection of walls of active and exposed parts of thedevice.
 24. The device for performing the process of formation of thecasing according to claim 22 characterized in that it further containsmechanisms (4) of additional functions, by which dispensers for addingthe additives are controlled and these dispensers may be at least: adispenser of coolant for cooling the hot and cold material forseparations/disruptions of the formed casing by the expansion joint,and/or dispensers of additive reinforcing materials for improving themechanical properties, and/or dispensers of foaming additives forimproving and treatment of thermal-insulation and mechanical propertiesof the casing walls.
 25. The device for performing the process offormation of the casing according to claim 22 characterized in that itfurther comprises group of channels for additives dosage control in aparticles division and acceleration block (6), where it generatesdifferently treated streams of materials, which form coaxial sandwichand composite structures of the casing, not only along the layers whichare layered in the casing, but also in radial direction relative to theaxis of the borehole.
 26. The device for performing the process offormation of the casing according to claim 22 characterized in that themechanical treatments module further comprises a separation andconcentration of the mixtures of rock particles and gases block (5), andit is a group of separators, by which division, separation and dischargeof the cooling gases is performed in the channels, where the coolinggases are separated and the mixtures of rock particles and gases areconcentrated to the desired concentrations.
 27. The device forperforming the process of formation of the casing according to claim 22characterized in that the particles acceleration blocks (6) areaccelerating centrifugal devices increasing the kinetic energy ofparticles.
 28. The device for performing the process of formation of thecasing according to claim 22 characterized in that the system (7) formixing the parts of the hot and cold streams from directing andaccelerating part is a mixer of streams of flowing hot and coldmaterials into the casing formation channel, wherein the particles arein the step of directing and acceleration directed and applied in thecasing layer in the casing formation channel.
 29. The device forperforming the process of formation of the casing according to claim 22characterized in that it further comprises a block (8) of sliding formsof pipelines in the casing, which is a system of moulding members, whichare designed for formation of the pipe channel in the layered part ofthe casing along the borehole.
 30. The device for performing the processof formation of the casing according to claim 22 characterized in thatthe output streams separator (10) is a separator at the outlet of thecasing formation channel, which separates excess materials dischargedout of the casing formation channel and parts of the hot gases fortempering the casing by controlled cooling.
 31. The device forperforming the process of formation of the casing according to claim 22characterized in that the heat treatments modules further contain ablock (11) for controlled cooling of the casing, which is a temperingand cooling system at interface of the layered casing and the device.32. The device for performing the process of formation of the casingaccording to claim 22 characterized in that it further comprises anoutlet (12) for waste products, which contains a system of outletchannels by which the collecting and cooling device discharges allexcess rocks and cooling gases materials, which are cooled to thetemperature below the temperature of the device resistance.
 33. Thedevice for performing the process of formation of the casing accordingto claim 22 characterized in that the system (7) for mixing theparticles consists of two systems of centrifugal channels, which areorientated against each other and lead into the channel of formation ofcasing layers application.
 34. The device for performing the process offormation of the casing according to claim 22 characterized in that thehot mixture formation generator (1) has an annular shape ofcross-section similar to the casing being formed and thereby it allowsto perform standard mechanical drilling (17) or core drilling in thecentral area of the annular casing formation.